Operating manual SV120

Operating manual SV120 C23556269_EN 11/2009 Rev. 0

Foreword Before setting up and commissioning the sliding vane compressor SV120, please read through this operating manual carefully. The operating manual contains important instructions which must be followed strictly if trouble-free operation and a long service life are to be ensured. Scope of application of the operating manual This operating manual only contains instructions for the sliding vane compressor SV120 of type D and H in combination with the respective accessory (compressor kit). This operating manual is valid only for operation of a compressor system, which was completed with ancillaries delivered by GHH RAND. Target group Use of the operating manual is exclusively restricted to qualified specialists. Instructions and safety instructions The following instructions and safety instructions are used in the operating manual to warn of dangers which could lead to operating errors, injuries and damage to property: Safety information Explanation of safety signal words DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. Caution Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury or property damage. Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property.

Table of Contents 1 General... 1 1.1 Application...1 1.2 Manufactuer's address...1 1.3 Identification...1 1.4 Information for enquiries and orders...1 1.5 Service locations...1 1.6 Technical data...2 1.7 Tightening torques...4 2 Safety... 5 2.1 General...5 2.2 Authorized personnel, training and qualification...5 2.3 Safety-conscious work...5 2.4 Safety instructions for the owner / operator...6 2.5 Unauthorized conversions and spare parts...6 2.6 Incorrect operating methods...6 2.7 Disposal / decommissioning...6 3 Operation... 7 3.1 Safety during operation...7 3.2 Initial commissioning...7 3.3 Switching on...7 3.4 Monitoring operation...8 3.5 Switching off...8 3.6 Storage...8 4 Maintenance / repair... 9 4.1 Safety...9 4.2 Tightening torques...9 4.3 Maintenance intervals...9 4.4 Maintenance work...10 5 Faults, causes and instructions for troubleshooting... 16

1 General 1.1 Application GHH RAND built and supplied the sliding vane compressor SV120 as a component of the SV120D (Direct Drive) or SV120H (Hydraulic Drive), compressor kits for installation on tanker trucks as a ready for connection unit. The compressors are mounted on tanker trucks and, because of the oil free compression of atmospheric air and the power-weight ratio, are used for the pneumatically assisted discharge of liquids, in cases where the use of pumps is difficult or impossible due to the problems caused by direct contact between liquid and pump. The products made and supplied by GHH RAND are designed for commercial vehicles applications for on road operation only. For all other uses, it is necessary to consult the manufacturer. 1.2 Manufacturer s address GHH RAND Schraubenkompressoren GmbH Max-Planck-Ring 27 46049 Oberhausen Germany 1.3 Identification The machine number is to be taken from the accompanying documents. In order to always have the number ready available, we recommend that you enter it into the following blank space. Mach. No. 1.4 Information for inquiries and orders If you have inquiries or orders for spare parts and accessories, please provide details of the exact type designation and the machine number of the compressor for which the spare part or accessory is intended. To ensure safety, use original spare parts and accessories authorized by the manufacturer. The use of spare parts and accessories which are not original or not authorized may exempt the manufacturer of any liability for the consequences. 1.5 Service locations For addresses of service locations, please see the last inside page of this operating manual or the internet page: http://www.ghhrand.com C23556269_EN 11/2009 Rev. 0 1

1.6 Technical data (ISO units) Dimensions & weights SV120 D H Length (approx.) mm 494 546 Width (approx.) mm 232 232 Height (approx.) mm 245 245 Weight (approx.) kg 37 39* *without hydraulic motor (option) Speed range SV120 D/H min. min -1 1000 max. min -1 1800 Maximum operating pressure SV120 max. 2.5 bar Performance data Performance data Unit SV120D/H Speed compressor min -1 1000 1400 1800 Discharge pressure bar(g) 1.5 Flow rate m 3 /h 75 119 163 Power at coupling kw 5.0 7.1 9.8 Discharge temperature C 136 133 142 Suction temperature, max. C 46 46 46 Discharge pressure bar(g) 2.0 Flow rate m 3 /h 65 109 152 Power at coupling kw 6.0 8.2 11.3 Discharge temperature C 164 157 166 Suction temperature, max. C 46 46 46 Discharge pressure bar(g) 2.5 Flow rate m 3 /h 55 98 140 Power at coupling kw 7.0 9.3 12.9 Discharge temperature C 192 181 190 Suction temperature, max. C 46 46 46 Discharge temperature at max. suction temperature C 240 227 238 All specifications for: Medium pumped: atmospheric air Suction pressure: 1 bar (abs.) Suction temperature: 20 C Technical data without loss of suction or pressure 2 C23556269_EN 11/2009 Rev. 0

1.6 Technical data (Imperial units) Dimensions & weights SV120 D H Length (approx.) inch 19.4 21.5 Width (approx.) inch 9.1 9.1 Height (approx.) inch 9.6 9.6 Weight (approx.) lb 82 86* * weight without hydraulic motor (option) Speed range SV120 D/H min. rpm 1000 max. rpm 1800 Maximum operating pressure SV120 max. 36 psig Performance data Performance data Unit SV120D/H Speed compressor rpm 1000 1400 1800 Discharge pressure psig 15.0 Flow rate cfm 50 76 102 Power at coupling hp 5.5 8.1 11.1 Discharge temperature F 229 231 247 Suction temperature, max. F 115 115 115 Discharge pressure psig 25.0 Flow rate cfm 42 67 93 Power at coupling hp 7.3 10.1 14.0 Discharge temperature F 299 290 306 Suction temperature, max. F 115 115 115 Discharge pressure psig 36.0 Flow rate cfm 32 58 83 Power at coupling hp 9.3 12.4 17.2 Discharge temperature F 375 356 372 Suction temperature, max. F 115 115 115 Discharge temperature at max. suction temperature F 464 441 460 All specifications for: Medium pumped: atmospheric air Suction pressure: 14.504 psia Suction temperature: 68 F Technical data without loss of suction or pressure C23556269_EN 11/2009 Rev. 0 3

1.7 Tightening torques Description Fastening screws (M10 40 10.9) compressor to fastening plate/foot Fastening screws (M12 35 8.8) compressor fastening plate to mounting bracket Screws (M10 40 8.8) suction/discharge port to compressor Screws (M6) shear bolts to overload coupling (optional) Tightening torque 58 Nm / 42.8 lbf ft 82 Nm / 60.5 lbf ft 50 Nm/ 36.9 lbf ft 10 Nm / 7.4 lbf ft 4 C23556269_EN 11/2009 Rev. 0

2 Safety 2.1 General This operating manual contains basic instructions to be followed during operation and maintenance / repair. This operating manual must be read by the responsible technical staff / operator prior to commissioning. This operating manual must always be available at the place of use of the compressor / accessory. 2.2 Authorized personnel, training and qualification Work performed on the compressor and the accessory, such as operation and maintenance / repair, must only be carried out by persons with the appropriate authorization, training and qualification, who are familiar with the valid safety regulations. Repair or retrofitting work may only be performed by authorized personnel; such persons are always available from the service locations or GHH RAND. 2.3 Safety-conscious work The important safety-related regulations for installation, operation and maintenance / repair of air compressors are contained in the following publications: The regulations of the professional associations, in particular: Standards, in particular: ISO 12100 Safety of machinery EN 1012-01 Compressors and vacuum pumps, safety requirements The following regulations and guidelines are to be observed in addition: Product-related safety data sheets in particular with regard to explosion protection, handling and storage Technical rules for hazardous materials (TRGS) Technical rules for operational safety (TRBS) The most recent valid issues of these regulations apply. Any special internal legal rules and regulations, particularly safety regulations, which apply due to local conditions, regions or environments must also be observed. If there are conflicting regulations, the stricter regulations are to be applied. You must also observe any national regulations in the respective country of use. C23556269_EN 11/2009 Rev. 0 5

2.4 Safety instructions for the owner / operator The owner / operator is responsible for ensuring that the sliding vane compressor / the compressor kit is in safe operational condition. Damaged or faulty parts must be replaced immediately. Keep safety / warning labels in a readable condition; replace, if necessary. Do not operate the unit in an area where flammable or potentially explosive gases are present, as they will be sucked in when operating the compressor. Always wear hearing protection when operating this unit, due to the high sound level of the compressor during operation. The supplied safety valve must be installed during installation of the compressor. Its purpose is to protect the compressor against exceeding the permissible operating pressure. Make sure that the tank / pressure vessel is equipped with a functional safety valve set to the permissible operating pressure. 2.5 Unauthorized conversions and spare parts Conversion and modifications to the sliding vane compressor / compressor kit are not permitted. If the seal is broken, the warranty is rendered null and void. To ensure safety, use original spare parts and accessories authorized by the manufacturer. The use of nonoriginal or non-authorized spare parts and accessories may exempt the manufacturer of any liability for the consequences. 2.6 Incorrect operating methods The sliding vane compressor and the compressor kit must be operated under the conditions stated in chapter 1.6 Technical data unless you have approval from GHH RAND stating otherwise. Operating the sliding vane compressor / the compressor kit under improper conditions may cause serious injury and considerable material damage. 2.7 Disposal / decommissioning Dispose of operating materials and parts after use in a proper and environmentally friendly manner. 6 C23556269_EN 11/2009 Rev. 0

3 Operation 3.1 Safety during operation Wear protective gloves! Risk of burns from hot machine parts. See also the safety instructions in Chapter 2 Safety. Do not operate the compressor in excess of the maximum discharge pressure of 2.5 bar (36 psig). If the maximum discharge pressure is exceeded, switch off the compressor immediately. In case of unusal operating noises, immediately switch off the compressor. For possible causes and actions to be taken, see Chapter 5 Faults, Causes and Instructions for Troubleshooting. 3.2 Initial commissioning Initial commissioning of the compressor is usually carried out by the system manufacturer. It includes checking the direction of rotation as well as a test run. For further information on the above points, please see the Installation and Service Instructions SV120. Leveling Park the vehicle in as level a position as possible. Maximum permitted inclination in machine direction when operating the sliding vane compressor: +/ 10 3.3 Switching on Switch on power take-off (PTO). Only start the compressor when completely depressurized. Never put it into operation if there is any back pressure. When the compressor drive shaft is not encased, make sure that no persons are near the drive shaft prior to switching on the power take-off. C23556269_EN 11/2009 Rev. 0 7

3.4 Monitoring operation 3.5 Switching off 3.6 Long-term storage Maintenance indicator 1 3 2 Switch off power take-off (PTO). Do not shut down the compressor when there is back pressure! If there is any back pressure, take appropriate measures for relieving pressure before switching off. Before the machine is installed, or if it has been removed from the driveline, and where it will be shut down for an extended period of time, then it should be stored in a clean and dry place. It is recommended to shrink wrap the compressor with water proof film with a desiccant pack inside the packaging. Where the compressor is mounted on a vehicle located outside, then the compressor should be operated for 15 minutes each week (twice per week in cold or damp conditions). The suction pressure in the suction pipe (1) to the compressor is displayed on the maintenance indicator (2). If a suction pressure of 50 mbar (0.94 psi) is reached (yellow plate (3) reaches red area Service ), the permissible suction pressure has been exceeded. In this case, clean the filter cartridge in the compressor s suction filter or, if the level of clogging is too high, replace the filter cartridge (see Chapter 4 Maintenance / repair ). Caution The inside of the compressor must by no means come into contact with an oily preservative as it may seriously damage the vanes when re-starting the compressor. 8 C23556269_EN 11/2009 Rev. 0

4 Maintenance / repair 4.1 Safety All checks and maintenance work must only be performed with the compressor switched off and depressurized. Wear protective gloves! Risk of burns from hot machine parts. Turn off the engine and remove the key from the truck s ignition before beginning any maintenance operation. See also the safety instructions in Chapter 2 Safety. When cleaning a tanker truck with a steam jet device, there is the possibility that water will seep into the inside of the compressor. In order to prevent corrosion, it is necessary to run the compressor briefly after cleaning (approx. 15 min.). 4.2 Tightening torques For more information about the required tightening torques, see Chapter 1.7 Tightening torques. 4.3 Maintenance intervals All of the maintenance and repair work listed on this page is described in detail in the following Chapter 4.4. Daily: Check the maintenance indicator and clean the suction filter, if necessary, or replace if it is extremely dirty. Weekly: Clean the compressor (cooling fins and covers). Run the compressor for approximately 15 minutes at least once a week. Check the suction filter and pipes for leaks. Monthly: Check the safety valve and the nonreturn valve for correct functioning. Check the suction and discharge pipes for leaks. Quarterly: Check the fastening screws of the compressor to the bracket. Clean the suction filter housing and filter cartridge, replace the filter cartridge if necessary. Annually: Check the piping and piping fixtures for corrosion and replace if necessary. C23556269_EN 11/2009 Rev. 0 9

Every 2 years / 1000 operating hours: Check the wear of the blades; Service compressor if necessary; refer to Installation and Service Instruction SV120. To ensure optimal operational safety and performance, it is recommended to service the compressor after every 1000 hours of operation (replacement of bearings and slide gate valve). 4.4 Maintenance work 4.4.1 Checking the maintenance indicator The design of the maintenance indicator allows reading of the suction pressure when the compressor is switched off. 4 3 Check the displayed value / position of the yellow indicator piston (1) of the maintenance indicator (2) If the yellow piston reaches the red area Service (4), the max. permissible suction pressure of 50 mbar (0.94 psi) is exceeded. In this case: Clean the suction filter - see Chapter 4.4.7. Push the button (3) in order to reset the maintenance indicator to Zero. 1 2 4.4.2 Cleaning the compressor Keep all the compressor connection ports shut. Ingress of foreign particles into the compressor may result in damage of the compressor. Prior to cleaning the compressor with a steam jet device / high pressure cleaner, let it cool down. Keep a minimum distance of 0.5 m (1.6 ft) when using a high pressure cleaner. Do not use any highly alkaline cleaners (bases) risk of corrosion! Rinse the components with pure water after using a cleaner. Remove any debris from the cooling fins of the compressor and the ventilation grid of the covers. In order to prevent corrosion, run the compressor briefly after cleaning (approximately 15 minutes). 10 C23556269_EN 11/2009 Rev. 0

4.4.3 Checking the suction filter and piping for leaks 1 2 4.4.4 Checking the safety and non-return valve 1 2 3 For North American safety valves, release the valve by pulling on the ring on the end of the valve to ensure the seat opens. Caution Don t check while the compressor is in operation. 3 Visually check the suction filter housing (1), rubber elbow (2) with maintenance indicator, pipe (3) as well as pipe connections and flanged connections on the compressor for leaks. Unscrew the knurled nut (1) of the safety valve (2). In the loosened state, the valve seat (3) must open. Replace safety valve if needed. When installing a new safety valve, pay due attention to the indications provided by the manufacturer. Tighten the knurled nut (1) of the safety valve (2). C23556269_EN 11/2009 Rev. 0 11

1 2 Combined safety and non-return valve: 1 Reach into the inlet port (2) with a finger. Inside the housing, push upwards the valve plate above the bore of the safety valve (4) and check that it is working smoothly. Replace the combined safety and non-return valve as necessary. 3 Remove the non-return valve (1). On the intake side of the non-return valve, push down the valve plate (2) on the shaft (see arrow) and check that it is working smoothly. If necessary, replace the non-return valve. Pay attention to the proper installation position of the non-return valve during assembly. The direction of flow of the non-return valve is indicated by an arrow (3) on the housing. 4 Loosen the screw connections on the flanges of the combined safety and non-return valve (1) and take off the valve together with the flange seals. Check the safety valve (3) as described before. Replace the safety valve, if needed. 2 3 When replacing the combined safety and non-return valve, the faultless safety valve can be screwed off and installed onto the new non-return valve. Install the safety / non-return valve with new seals onto the flanges of the discharge pipe. Pay attention to the proper installation position of the combined safety and non-return valve during assembly. The direction of flow of the non-return valve is indicated by an arrow on the housing. Always use new gaskets when reinstalling on the flanges of the discharge pipe. 12 C23556269_EN 11/2009 Rev. 0

4.4.5 Checking the compressor fastening 1 4.4.6 Cleaning the suction filter Caution Do not clean the air filter cartridge by means of compressed air or liquids. Clean the filter cartridge by lightly beating on it. Replace the filter cartridge if needed. Assembly occurs in reverse order. 3 2 3 1 2 3 When installing the cover, make sure that the dust separator valve points vertically down. (See the OBEN/TOP mark on the front side of the cover.) Check the four fastening screws (3) of the compressor on the fastening plate; re-tigthen them cross-wise at a torque of 58 Nm (42.8 lbf ft), if necessary. Check screwed connections (2; total 4) of the fastening plate to the mounting bracket; re-tighten nuts cross-wise at 82 Nm (60.5 lbf ft), if necessary; lock the screws on the back when doing so. Check the screwed connections (1; 4 min.) of the mounting bracket to the truck chassis. 5 4 Push down the snap fits (2) on the left and right-hand side of the cover (1) and remove the cover from the air filter housing (4). Pull out the filter cartridge (3). Clean the inside of the filter housing. Press together the dust separator valve (5) on the cover such that the rubber lips open and the dirt collected inside can fall out. C23556269_EN 11/2009 Rev. 0 13

4.4.7 Checking the wear of the vanes 1 2 5 Loosen the nuts (1) on the discharge port of the compressor and remove them together with the washers (2) from the fastening screws (5). The discharge port is the port at which the direction of rotation arrow (6) points. 5 1 2 3 4 6 Remove the flange (3) of the discharge pipe from the compressor and put the discharge pipe aside. Remove and discard the gasket and remove the screws (5) from the compressor flange. Make sure that no foreign particles enter the compressor through the open discharge flange. Ingress of foreign particles into the compressor may result in damage of the compressor. Do not reach into the compressor ports with your hands - risk of injury through shearing! 1 A 2 Through the discharge port (2), visually line up the rotor slot (3) and then carefully insert a max. 5 mm (0.2 inches) thick, clean device into the rotor slot (3) and push it forward up to the upper edge of the vane (4). Manually turn the rotor by hand in the indicated direction of rotation to line up the rotor slot (see direction of rotation arrow on the housing), if necessary. Mark the device at the level of the compressor flange and pull it out of the compressor again. Measure the distance A. 4 3 14 C23556269_EN 11/2009 Rev. 0

When the value of A exceeds 105 mm (4.13 inches), it is recommended to replace the vanes or conduct maintenance due to the wear of the vanes. See Installation and Service Manual. When the value of A is below or equal 105 mm (4.13 inches), the length of the vanes is usually sufficient until the next maintenance date; in this case: Screw back on the discharge pipe with new gasket onto the compressor. Always insert the screw heads into the slot on the compressor flange. Otherwise, the compressor housing may be damaged depending on the length of the screw. Do not use electro-conductive gaskets due to the risk of corrosion! Further operation of the compressor with the vanes worn may result in damage of the rotor and the compressor housing; this in turn results in an excessive wear / shorter life of new vanes. 4.4.8 Replacing the shear bolts of the overload clutch Prior to fitting in new shear bolts, find the reason why they sheared off, see chapter 5 Faults, causes and instructions for troubleshooting. Check free rotatability of the compressor by turning the drive shaft. The bolts (1) of the overload clutch (3, optional) can shear off if the torque is too high. They have to be replaced as described below: Unscrew the hexagon socket screws (2) and remove the shear bolts (1). 1 3 2 Fit in new shear bolts (marked BG [blue-green]) and fix them with the hexagon socket screws M6 (2) (tightening torque = 10 Nm (7.4 lbf ft)). C23556269_EN 11/2009 Rev. 0 15

5 Faults, causes and instructions for troubleshooting If in doubt, turn off the compressor! Fault Possible cause Remedy Chapter Volume air flow not sufficient Discharge pressure too high Discharge temperature too high Suction pressure exceeds 50 mbar (0.94 psi) Too loud or unusual running noise Compressor does not work Drive speed too low Increase drive speed to the maximum permitted speed 1.6 Suction filter soiled/clogged Clean or replace filter cartridge as necessary 4.4.1 / 4.4.6 Suction hose kinked Check suction hose; re-install as necessary Nominal diameter of the discharge pipe Install new pipes with a larger nominal diameter too small Non-return valve faulty Check the non-return valve 4.4.4 Safety valve does not open Check the safety valve 4.4.4 Drive speed too high Reduce the drive speed to the maximum permitted speed 1.6 / 1.7 Suction filter soiled / clogged Clean or replace the filter cartridge as necessary 4.4.1 / 4.4.6 Cooling fans compressor housing / Clean the compressor 4.4.2 fan covers dirty / clogged Discharge pressure too high Check the safety valve 4.4.4 Ambient temperature too high Observe permitted suction temperature 1.6 Compressor vanes worn / stuck in rotor slots Repair the compressor see Installation / Service Manual Suction filter dirty / clogged Clean or replace the filter cartridge as necessary 4.4.1 / 4.4.6 Suction hose kinked Check the suction hose; re-insall as necessary Drive speed too low Increase drive speed up to the minimum permitted speed Vanes worn or damaged / surface of compressor bore damaged Shear bolts sheared off Repair the compressor see Installation / Service Manual Replace the shear bolts; identify and rectify reason for 4.4.8 excessive torque 16 C23556269_EN 11/2009 Rev. 0

Fault Possible cause Remedy Chapter Shear bolts sheared off repeatedly Compressor switched on/off under Relieve pressure 3.3 / 3.5 back pressure For manual transmissions: Engage clutch at slower rate clutch engagement too fast For automatic transmissions: Have parameters changed by service center coupling times too short Compressor defective Replace compressor C23556269_EN 11/2009 Rev. 0 17

Notes 18 C23556269_EN 11/2009 Rev. 0

Service GHH RAND Schraubenkompressoren GmbH Max-Planck-Ring 27 D-46049 Oberhausen, Germany Service Hotline Tel. (+49) 208 / 99 94-177 Service Tel. (+49) 208 / 99 94-170 Spare Parts Tel. (+49) 208 / 99 94-171 Fax (+49) 208 / 99 94-179 E-Mail Internet info_ghh-rand@irco.com www.ghhrand.com Printed in Germany The technical details are subject to change and may vary from the information and illustrations in the operating manual. This document must not be reprinted, translated or reproduced, either in part or in full, without prior written permission.

GHH RAND Schraubenkompressoren GmbH Max-Planck-Ring 27 D-46049 Oberhausen Service Hotline Tel. (+49) 208 / 99 94-177 Fax (+49) 208 / 99 94-179 Subject to revision without notice Printed in the Federal Republic of Germany 11/2009 EN As a contribution to environmental protection, this paper has been produced from 100% chlorine-free bleached pulp.